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When Replacing Electrical Items in the Mast

Re-wiring and replacing the fixtures in the mast is a task that most of us boat owners need to face at some point. Let’s address what needs to happen during this process and what is the most efficient way to do this.

First, the mast needs to be un-stepped. Therefore it could be a smart idea to handle any other items that could benefit from the mast being out. Next, begin by removing the old masthead fixture, the old steaming light fixture, and the old VHF antenna. Now remove all of the old wires and any remaining hardware. In some cases there are electrical items that need to be re-used. These items could be a radar and cable, as well as a digital wind instrument. Be sure to carefully remove these items as well and inspect them closely (now’s the time).

~CLICK ANY OF THE ABOVE IMAGES TO LINK TO THE MANUFACTURER’S WEBPAGE!~

Once all electrical items have been removed, you should check to see if there is a conduit present and how it may or may not be fastened. A properly installed conduit offers; no wire slap, clean wire runs, and most importantly, the ability to run additional wires or trouble shoot existing ones with ease, even when the mast is up.

Installing a conduit is a bit’ of a ‘trick of the trade’. It is best here to seek the assistance of a professional rigger if one needs to be installed. Make sure to ask your rigger what technique he or she might use. At T.R.C., we will use aluminum or PVC irrigation tubing. This type of tubing offers a sleeker connection at the joint. Our conduits are then riveted using a pair of aluminum rivets (to avoid dissimilar metals) every 3′ or so along the length of the mast. I like to counter sink these rivets because it makes it look more finished and also gives you no issues if there might be future sanding. After the conduit is ready to go, you are now ready to fish-in a messenger line. From here you can begin to pull in your new wires. Always try and leave in a service messenger when finished. Unless the conduit is full of course, we don’t want to be misleading anyone in the future. I tend to make it a practice to pull-in the large wires or the wires with permanent ends first. Now go ahead and drill, tap, and dry fit your new fixtures. Make sure you take your time and think it through and follow the manufacturers guidelines. Never use sheet metal or self tapping screws, even if provided by some manufacturers. Always drill and tap, or rivet your fixtures along with a dab of sealant for a secure hold.

Make sure you use marine grade connectors that heat shrink. Additionally, before making any connections, slide on a piece of marine grade heat shrink tubing. Marine grade heat shrink tubing has an adhesive that is released when heated. After your connections are made and heat shrunk, make sure to provide some sort of strain relief for the cables (pictured below). Next, install the fixtures permanently using a sealant as an isolation barrier. Pull out any remaining slack at the butt of the mast. Trim all of your cables to a neat and even length. Leave enough slack for service lengths. Finally test all of the light fixtures through the mast and label the cables accordingly. As always, don’t be afraid to ask, so leave a comment or ask a question, we will reply. Thanks for the read!

32 thoughts on “When Replacing Electrical Items in the Mast”

I read all the questions and comments, but my problem is this; I have a 1987 Hunter 26.5 with a Fractional Rig, I have an Anchor Light at the top of the mast, and a steaming light above the spreaders. There are two wires coming out of two holes near the bottom of the mast. One appears to have a connector on the end and one is just two bare wires. There is one connector on the deck. The problem I have is the connector on the one wire has no way of going into that connector on the deck. The deck connector has a screw top, that I assume holds the connector from the mast in place, but that connector on the one wire will not fit through that screw cap, plus I see no connection in the deck connector that it can plug into. In the cabin I see some wires going up into the cabin top but have no idea what they are, there is a nail that seems to be holding the wires into the hole in the cabin top. Being this is a used boat and sailed on a lake most of her life, I’m thinking they had no need for either light so the wiring is original and I have no idea what the two wires in the mast are connected to, nor even if the lights work. The previous owner told me you only plug the wire with the connector on it in and forget about the other wire, but since I can’t figure out how to connect it I’m at a lose as to what to do, the marina I’m in told me to forget about the lights for now as they won’t be needed, but you know as a stickler for doing thing right, I want at least the Steaming light working, the Anchor light can wait until next season as I have no plans to anchor anywhere at this time. Thing is I have a plan to install a Windex light for my Windex Windvane, and replacing my Steaming light with a combo Steaming light and Deck light. The Steaming light and Windex light would be on the same circuit as the Navigation lights, and the Anchor light and Deck light would be independent of all other lights. That would be three wires coming down the mast to one connector on the deck, call me crazy, but how do you connect three wires to one connector and have them work like I need them to? Am I missing something here? I see photos of my boat with the two wires coming off the mast, but the photos are cut off before reaching the deck, so I can’t see how they are connected to the deck.

Can we start with some pictures of the wires, fixtures and the deck connections that you are using for this. Shoot us your phone number with this as it will likely be easier to explain via telephone once I see the pictures and wrap my mind around things.

This shows the two wires coming out of the mast, one has a connector as you can see, the other is bare wires…

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Its really hard to see, but the light area at the end of the wire is bare…out of focus, I know…

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This is my Anchor light, assuming one of those wires is from here…

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Hard to see, but right under the white cable loop beneath the spreader is the top ov the deck connector…

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A bit out of focus, but in the same spot as above photo is the deck connector, the top of that connector unscrews from the deck part it has a hole through it and it would appear to somehow hold the connector on the wire coming from the mast to the deck portion of the deck connector. The plug you saw will not in any way fit into that unscrewed top piece nor the opened deck connector. So Im not sure how its supposed to work. And right now, Im not sure which wire is which, one, I assume, goes the the Anchor light, and the other goes to the Mast/Steaming light, of which I have no photos of.

Sometimes we have to stick a drill bit into the spot where there enters the conduit and open the hole for a fair-er lead. We then use a steel fish tape with a short messenger, hitched and taped onto the end of it. We tie a loop in it so that it is easy to pick out. Once we see the messenger, or the fish tape (can take some patience), we pick it out with a small welding rod with a tiny hook bent into the end of it. A metal hanger may suffice, but the hook needs to be small enough to hook the fish tape and pull it out of the small hole. We then string a messenger in place. We do this for all wire exits first before we make any actual wire runs.

How in the world do you pop rivet plastic conduit inside the extrusion every three feet? How are you drilling , holding the conduit through the mast???

I have a 1979 Catalina 27. We have the mast on saw horses. Cleaned off the old, redundant fittings. Ready to install new lights, wiring harness and antenna. I have read of people gluing a conduit in the mast. Your thoughts?
Thanks
Jim

Well that’s why I said…”It’s a bit of a trick-of-the-trade”, but check out my response from a few comments below….

To pull the conduit to the mast wall once it is inside the mast (loose) we make a special tool that we call a “conduit hook” out of a very stiff piece of rod rigging measuring just under 3/16″ of an inch. You probably don’t have access to this, plus it is very hard to bend. Another technique is to figure how you want the conduit to run, then tape it onto the outside of the mast and drill all the way through the conduit and into the mast wall. Then remove the conduit from the outside of the mast. Counter sink all mast wall holes so that the rivet head will be submerged. Then, roll the mast with the holes facing down, this way gravity will work with you, line up the first set of holes and pop your rivet. If you lined it up right the next holes should be right there and so on…

Thanks. I kept reading and finally went…duh. When i pulled the wires yesterday, they all had long zip ties and one piece of string with a big wad of seat cushion foam. No wonder we never had the first noise from that mast. Anyway, the long zip ties are elected. Boats wiring lasted many tears before I got it. We plan for a bigger boat next year. This is our boot camp boat. I’m also not installing a tabernacle hinge, even though we bought one. Now, if I could find the wiring schematic from the PO. naw…. never happen.. Appreciate your work.

It is likely that you may just be better off buying an entire new VHF and go aloft and install it. This should just screw into the new cable (if the fitting is still okay) and you’ll be all set. Hope that helps.

This may be a better question for a marine electrician. We use 16 a lot and 14 or 12 for bigger boats. However I see no reason you can’t use 18 awg especially given that all lights are LED now.

I think the answer may lie in how long the wire run is, and how much current draw does it need to support? I would like a second a opinion from a marine electrician on that one to be sure. Anyone? Bueler?

Long answer short….as long as you used a marine grade wire, I’ll bet it will be fine.

~T.R.C.

P.S. is the wire really aluminum? I thought it was tin coated copper no?

How do you hold on to the conduit when you are drilling the holes for the rivets? Also I assume you glue the PVC pipe together and then slide it into the mast? Could you put the messenger line in then or is their an easy way when the conduit is in the mast?
Thanks for your help.

We would run the messenger via a Fish Tape after the conduit is in. Our drill bit would otherwise snag it when drilling to mount the conduit. Use thin wall’d irrigation tubing with bell ends, 1″ to 1-1/4″ should do it. We have glued them in the past, but now we just install with the bell facing the mast head. The fit is snug enough to keep everything in place until we slide it into the mast. Then once fastened (every 3-4′) it can’t come undone, plus gravity is working with us once the mas goes up.

To pull the conduit to the mast wall once it is inside the mast (loose) we make a special tool that we call a “conduit hook” out of a very stiff piece of rod rigging measuring just under 3/16″ of an inch. You probably don’t have access to this, plus it is very hard to bend. Another technique is to figure how you want the conduit to run, then tape it onto the outside of the mast and drill all the way through the conduit and into the mast wall. Then remove the conduit from the outside of the mast. Counter sink all mast wall holes so that the rivet head will be submerged. Then, roll the mast with the holes facing down, this way gravity will work with you, line up the first set of holes and pop your rivet. If you lined it up right the next holes should be right there and so on…

> The Rigging Company, LLP commented: “Hi Bob, We would run the messenger > via a Fish Tape after the conduit is in. Our drill bit would otherwise snag > it when drilling to mount the conduit. Use thin wall’d irrigation tubing > with bell ends, 1″ to 1-1/4″ should do it. We have glued them in the p” >

I’m preparing to rewire the mast on my Beneteau First 456 with a keel stepped mast and have a few questions.

1) Currently each of the electrical wires and antenna coax exits the mast just above the deck and then connect to a series of water tight deck fittings. Is there a smarter (lower loss, less damage prone) way to get the wires below deck? I’ve considered running the connectors internally to near the base and exiting there.

2) My plan is to use RG-213 for the VHF, is there a better alternative?

3) I don’t know if there is a wiring conduit on the boat currently. On a previous smaller (27 ft) boat I used 3M 5200 to glue pvc schedule 40 to the inside of the mast as conduit with good success. What are your thoughts/concerns on that as technique on a larger boat (air draft 65′)?

4) Do you have any suggestions for illuminating the sails enough to see tell-tales at night without destroying the crews night vision? We frequently race at night and have tried several glow in the dark products but end up just shining a red lens flashlight on the sail periodically.

1. There are some other options. Depending on the mast step style, and granted the mast has been removed, you can remove the mast step, locate and drill a smart hole at the required diameter (1″ or so, depending on what your wire bundle requires), and weld a 2-3″ Hawse Pipe to step at this location. You can bring the wires into the boat this way and make the connections below deck. You can alternatively bring the connections above deck and inside the mast, but this will require an access cutout and door (big enough for your hand to fit into) to be made a few inches above the mast butt. This will give you access to connect and disconnect the wires before stepping and unstepping.

Another way is to install a stainless steel Hawse Pipe (6-8″ long, again w/ a diameter big enough to accommodate the wire bundle) next to the mast. The piece of tubing needs to have 180 degree bend so that the opening faces the deck and forces the wire into a drip loop. Then have a round (donut style) base for the mounting welded to its straight end. The bend needs to face aft to dissuade any rushing water from entering the boat. Connections here are also made below deck.

2. You may be able to get away with using RG8X. You are right on the edge given the boat’s size, depending on the wire length, signal degradation becomes a concern. We use RG8X more than any other wire when it comes to VHF cables, but most of our customers are in the 35-45 foot boat range…Chesapeake Bay. It uses up less space in the conduit and utilizes solder-less PL-259 connectors, easy-peasy. A marine electrician is a much better resource for this question.

3. There is very likely a conduit for the Z Spar (US Spars) mast or the Sparcraft Masts. However, the way either of this companies secure the conduit is were the trouble lies. IF the conduit is still in good standing, and hasn’t become dislodged aloft (common issue with these, as they are split length wise and slid onto a “T” in the extrusion), gently pull out all of the old wires, one at a time. THEN, install a rivet (or a screw) right beneath the bottom of the conduit. This will ensure that it doesn’t slide down onto the wires when vertical (another common problem with the Bene’s).

….and no to the 5200 idea. If the conduit needs to be re-done it should be installed like the factory version with the stop at the bottom (like I just described). Or you can have it done the right way which is rivet the conduit to the mast wall every 3-4′ using two aluminum rivets. That is the best solution. You can call us for tips and tricks on this method if you like. We’d be glad to help discuss.

4. I think a couple of cleverly mounted mast accent lights on top of the spreaders may do the trick for the main. Check out our friends over at OGM….https://orcagreenmarine.com/product/kis-led-swivel-uplight/. She has devised a pretty clever bracket that fits many applications an adjusts to almost any angle. I am willing to bet that if you call her she can come up with a luff light mount for the Genoa as well.

I have a 4″ x 6″ elliptical mast, .180″ thick. All my other new wires are IN the mast even the RG213 ant. cable . Now I have LED spreader lamps on both P & S , this is the ONLY wire that seemingly has to run externally from P to Stb. The spreader mounts are solid alum castings you see. So I reckon I need to drill 2 holes P & s in my mast for those leads to leave the mast and travel to the lamps externally? Any other ideas? alternatives? Thanks for the open forum !

Thanks for asking and although your approach will work, yes you do have another, cleaner solution for this. The way we do it is drill a hole above the the spreader base, port and starboard. Then drill a hole on top of the spreader just outboard enough so that it won’t interfere with the spreader base when installed. Then on the underside of the spreader you drill the final wiring exit to go to the light, right beind the light. This will make for a cleaner look from the deck, no wires.

Hi Raul. Yes, we have come across many versions of how conduit can be installed. Everything from U Bolts, spray in foam, cellular foam zip tied to wires every three feet or so, conduit cut length wise and slipped onto a groove inside the mast, if present,….non of which I’d recommend.

As mentioned in the article, we like the PVC tubing over irrigation tubing is the connection joint is sleeker and allows for better mounting, flush to the inside of the mast wall.

Correct. No snags yet…20 years of doing it this way. The pulled end of the rivet usually ends up very rounded. So problems there. Yes, we rivet the PVC tubing. It is just to keep the PVC flush with the mast wall and hold it in place.

I have forespar steaming/ deck light and separate spreader lights. My spreader lights. Can be switched on / off. My steaming lights can be switched on/ off. But I cannot get my deck light to come on with my spreader lights without lighting up several indicator lamps on my electrical panel.
What am I doing wrong?

Do you have the phone number to MISEA group. Their website is down and a I need an installation diagram of the wiring for their led anchor light. Thanks
Also, In the above photo two cables are run through the mast without protection from abrasion.Unless by taping them together is good enough. Is their a thin push-in grommet of some sort?

and yes a rubber grommet would be a good idea there. Keep in mind not only is there the tape to handle the chafe protection. Ancor wires a covered in another white sheath which will further help with chafe protection.

Hi, I have the same Forespar ML II steaming/spreader light you show above. With the relatively light weight wires in the fixture, I’m wondering how you provided strain relief for the wiring with this mount? I have 14GA triplex which seems may be heavy for the small wires to support inside the mast, but the light fixture doesn’t seem to provide a lot of space between it and the mast to accommodate the wiring and a clamp.

Thanks for the comment. A good question. I would butt connect the wires with marine grade heat shrink fittings and then heat shrink another service over the top of that. While everything is still warm, I ‘Z’ fold the first 4-5 inches or so coming out of the light. I pinch these 1-2 folds inbetween the light and the mast (just off of centerline either way there is usually a small amount of space for this) with the connection outside of the mast so that any strain is on the large wires, not the connection.
If the light wire exit is below or above the light itself (vs. directly behind it), then a stainless steel cable clamp may be the best choice. The main thing is that the strain is always on the big wire and not the connection.
14 gauge does seem thick for any boat smaller than 46′.